Construction of a building

ABSTRACT

A method of forming a lift shaft or similar in a multi-storey building is disclosed. The method includes the casting the shaft in segments (typically in the order of 800 mm deep) and then assembling the segments atop each other to form the shaft. The segments have vertical passages which align to form channels in which rebar can be inserted to tie the structure together.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application relates and claims priority to Australian Innovation Patent number 2021107156, filed 25 Aug. 2021, the entirety of which is hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to the construction of buildings. The invention has been primarily created in relation to lift shafts, stair cores and similar inter-storey structures in multi-storey buildings, but is considered to have wider application including to the construction of columns and walls.

BACKGROUND TO THE INVENTION

In “mid-rise” (typically two to eight storey) construction there must be means to travel between storeys. Typically, this is done via lifts (elevators) or stairs. In both cases, a four-walled structure is required which extends through multiple building storeys. For convenience, the following description will refer to lift shafts, although it is equally applicable to stair cores.

In mid-rise construction there are three methods which are commonly used to form lift shafts. The first is to lay load bearing masonry blocks in a traditional manner, then add reinforcement, and core-fill. The second is to use precast panels. The third method is to cast in situ by pouring concrete within a formwork system which includes reinforcing. The latter can include systems where the formwork forms an outer skin on the finished lift shaft, or formwork arranged to be removed to leave a concrete wall.

There are difficulties involved with each of these methods. Block walls are slow to erect, and require skilled tradespeople. Precast panels are heavy, and require a large crane on-site. Poured concrete in finished formwork systems provide little ability to verify reinforcement and concrete condition. Removable formwork is both expensive and labour-intensive.

The present invention seeks to propose an alternative system for the construction of lift shafts, stair cores and the like.

SUMMARY OF THE INVENTION

According to one aspect of the present invention there is provided a method of constructing an inter-storey structure within a multi-storey building, the method including the steps of:

pre-forming shaft segments, each shaft segment being rectangular in cross section;

locating a first shaft segment at a required location within the multi-storey building; and

sequentially mounting additional shaft segments atop the first shaft segment to form the inter-storey structure.

The term ‘shaft segment’ will be understood to refer to segments of lift shafts, stair cores and other similar inter-storey structures.

It will be appreciated that although the shaft segments have been described as being rectangular in cross section, this includes segments which have gaps in one wall, for instance to form openings into the inter-storey structure.

It is preferred that each shaft segment has at least one vertical passage extending within a wall of the shaft segment. The passage is preferably formed by a tube cast within a wall of the shaft segment, the tube extending vertically. These passages can be aligned to form a vertically extending channel through the inter-storey structure.

The method includes the further step of locating reinforcing rods within the vertically extending channel(s) of the inter-storey structure. The vertically extending channel(s) can then be filled with a curable substance such as a grout.

It is preferred that the reinforcing rods are longer than the vertically extending channels. In a preferred embodiment, the reinforcing rods extend through the first shaft segment and into aligned holes beneath the first shaft segment. In the preferred embodiment the reinforcing rods also extend above the top of the inter-storey structure, providing a ‘tie point’ for a higher structure (which may be a further inter-storey structure).

It will be appreciated that each shaft segment has four corners which are cast into position, thus providing structural integrity. This is in contrast to the use of pre-cast panels, in which the corners must be joined by a weld plate.

It is anticipated that each shaft segment is likely to have a height in the order of 800 mm.

According to a second aspect of the present invention there is provided a method of constructing a building wall, the method including the steps of:

pre-forming wall segments, each wall segment being rectangular in cross section and having at least one vertical channel extending therethrough;

locating a wall segment at a required location within the building;

sequentially mounting additional wall segments atop the first wall segment to form the building wall;

locating reinforcing rods within the vertically extending channel(s) of the wall segments; and

filling the vertically extending channel(s) with a curable substance.

According to a third aspect of the present invention there is provided a method of constructing a building column, the method including the steps of:

pre-forming column segments, each column segment being T-shaped in cross section and having at least one vertical channel extending therethrough;

locating a column segment at a required location within the building;

sequentially mounting additional column segments atop the first column segment to form the building column;

locating reinforcing rods within the vertically extending channel(s) of the column segments; and

filling the vertically extending channel(s) with a curable substance.

According to a fourth aspect of the present invention there is provided a method of constructing a building corner, the method including the steps of:

pre-forming corner segments, each corner segment being L-shaped in cross section and having at least one vertical channel extending therethrough;

locating a corner segment at a required location within the building;

sequentially mounting additional corner segments atop the first corner segment to form the building corner;

locating reinforcing rods within the vertically extending channel(s) of the corner segments; and

filling the vertically extending channel(s) with a curable substance.

BRIEF DESCRIPTION OF THE DRAWINGS

It will be convenient to further describe the invention with reference to preferred embodiments of the present invention. Other embodiments are possible, and consequently the particularity of the following discussion is not to be understood as superseding the generality of the preceding description of the invention. In the drawings:

FIG. 1 is a plan view of a lift shaft constructed in accordance with prior art techniques;

FIG. 2 is a front view of the lift shaft of FIG. 1 ;

FIG. 3 is a plan view of a lift shaft in accordance with the present invention;

FIG. 4 is a front view of the lift shaft of FIG. 3 , showing hidden elements;

FIG. 5 is a schematic perspective of the lift shaft of FIG. 3 ;

FIG. 6 is a schematic exploded view of the lift shaft of FIG. 3 ;

FIG. 7 is a plan view of a wall section in accordance with the present invention;

FIG. 8 is a front view of the wall section of FIG. 7 ;

FIG. 9 is a perspective of the wall section of FIG. 7 ;

FIG. 10 is a perspective of a wall portion constructed from wall sections as shown in FIG. 7 ;

FIG. 11 is a front view of a footing block in accordance with the present invention;

FIG. 12 is plan view of the footing block of FIG. 11 ;

FIG. 13 is a perspective of the footing block of FIG. 11 ;

FIG. 14 a schematic exploded view of a wall formed using footing blocks as shown in FIG. 11 together with wall sections as shown in FIG. 7 .

FIG. 15 is a plan view of a column section in accordance with the present invention;

FIG. 16 is a front view of the column section of FIG. 15 ;

FIG. 17 is a perspective of the column section of FIG. 15 ;

FIG. 18 is a perspective of a building column constructed from column sections as shown in FIG. 15 ;

FIG. 19 is a plan view of a corner section in accordance with the present invention;

FIG. 20 is a front view of the corner section of FIG. 19 ;

FIG. 21 is a perspective of the corner section of FIG. 19 ; and

FIG. 22 is a perspective of a building corner constructed from corner sections as shown in FIG. 19 .

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to the Figures, FIGS. 1 and 2 show a lift shaft 10 having a rear wall 12, two side walls 14 and a front wall 16. The front wall 16 includes an opening 18 to serve as a doorway. The lift shaft 10 has been constructed in a single piece, using concrete poured into framework as known in the prior art.

FIGS. 3 to 5 show a lift shaft 20 formed in accordance with the present invention. The lift shaft 20 has a rear wall 22, two side walls 24, and a front wall 26. The front wall 26 includes an opening 28 to serve as a doorway.

The lift shaft 20 is formed of four segments: a first segment 30, a second segment 32, a third segment 34 and a fourth segment 36.

The first segment 30 is rectangular in cross section, having a height of about 800 mm. The first segment 30 has a rear wall 22, two side walls 24 perpendicular to the rear wall 22, and a front wall 26 parallel to the rear wall 22. The front wall 26 has a first portion 38 spaced from a second portion 40 by an opening 28.

The second segment 32 is the same size and shape as the first segment 30.

The third segment 34 is similar to the first and second segments 30, 32, except its front wall 26 extends from one side wall 24 to the other side wall 24, with an opening 28 extending only about half-way up the height of the front wall 26.

The fourth segment 36 is similar again, but with a complete front wall 26 having no opening.

Each segment 30, 32, 34, 36 has two vertical passages 42 formed in its front wall 26, in the first portion 38. The vertical passages 42 are formed by tubes cast with the front wall 26. The vertical passages 42 of each segment 30, 32, 34, 36 are aligned so as to form vertical channels 44 which extend through the lift shaft 20.

The lift shaft 20 is constructed by first locating the first segment 30 in its required position within a building. The building includes apertures (not shown) arranged to align with the vertical tubes 42 of the first segment 30.

The second segment 32 can then be lowered into position atop the first segment 30, with the opening 28 and the tubes 42 of the second segment 32 aligning with the opening 28 and the tubes 42 of the first segment 30.

Similarly, the third segment 34 and the fourth segment 36 can be lowered into position to complete the lift shaft 20.

The segments 30, 32, 34, 36 are ‘tied’ together by the use of reinforcing rods 46 such as 20 mm rebar. A rod 46 is inserted within each channel 44, extending into the aligned aperture in the building. The rod 46 is long enough to protrude from the top of the channel 44. The channels 44 can then be filled with grout.

The protruding portions of the rod 46 can be used to provide a ‘starter’ bar for another section of the shaft.

It will be appreciated that the weight of each segment 30, 32, 34 36 is sufficiently small to be able to be lifted by a self-erecting crane as commonly used on mid-rise building sites.

It will be further appreciated that the corners of the lift shaft 20 are cast as such, rather than requiring panels to be bolted together.

Although the invention has been described with the use of two channels 44 and corresponding rods 46, it will be appreciated that in use a plurality of channels 44 spaced around the periphery of the lift shaft 20 are likely to be employed.

It will be appreciated that the principles described above can be used to construct other elements of a building assembly.

FIGS. 8 to 10 show construction of a building wall 50 from a plurality of wall segments 52. The wall segments 52 are rectangular in cross section, and are generally elongate. They each include a plurality of vertical tubes 42, which align together to form channels 44. The wall segments 52 can be tied together using reinforcing rods 46 and grout as described above.

FIGS. 11 to 14 show a footing block 54, which is generally L-shaped in cross section, having a horizontal pad 56 arranged to rest on the ground and a vertical portion 58 extending from a rear of the pad 56. The vertical portion includes a plurality of vertical tubes 42. A wall such as a retaining wall can be constructed by placing a plurality of footing blocks 54 alongside each other, and then locating wall segments 52 above the footing blocks 54. The wall segments 52 can be tied to each other and to the footing blocks 54 using reinforcing rods 46 and grout.

FIGS. 15 to 19 show construction of a T-shaped building column 60 from a plurality of T-shaped column segments 62. The column segments 62 each include a plurality of vertical tubes 42, which align together to form channels 44. The column segments 62 can be tied together using reinforcing rods 46 and grout as described above.

FIGS. 20 to 22 show construction of a building corner 70 from a plurality of L-shaped corner segments 72. The corner segments 72 each include a plurality of vertical tubes 42, which align together to form channels 44. The corner segments 72 can be tied together using reinforcing rods 46 and grout as described above.

Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention. 

What is claimed is:
 1. A method of constructing an inter-storey structure within a multi-storey building, the method including the steps of: pre-forming shaft segments, each shaft segment being rectangular in cross section; locating a first shaft segment at a required location within the multi-storey building; and sequentially mounting additional shaft segments atop the first shaft segment to form the inter-storey structure.
 2. A method of constructing an inter-storey structure as claimed in claim 1, wherein each shaft segment has at least vertical passage extending within a wall of the shaft segment.
 3. A method of constructing an inter-storey structure as claimed in claim 2, wherein each passage is formed by a tube cast within a wall of the shaft segment, the tube extending vertically.
 4. A method of constructing an inter-storey structure as claimed in claim 2, wherein the passages are aligned to form a vertically extending channel through the inter-storey structure.
 5. A method of constructing an inter-storey structure as claimed in claim 4, wherein the method includes the further step of locating reinforcing rods within the vertically extending channel(s) of the inter-storey structure.
 6. A method of constructing an inter-storey structure as claimed in claim 5, wherein the method includes the further step of filling the vertically extending channel(s) with a curable substance.
 7. A method of constructing an inter-storey structure as claimed in claim 5, wherein the reinforcing rods are longer than the vertically extending channels.
 8. A method of constructing an inter-storey structure as claimed in claim 7, wherein the reinforcing rods extend through the first shaft segment and into aligned holes beneath the first shaft segment.
 9. A method of constructing an inter-storey structure as claimed in claim 7, wherein the reinforcing rods extend above the top of the inter-storey structure.
 10. A method of constructing an inter-storey structure as claimed in claim 1, wherein each shaft segment has a height in the order of 800 mm.
 11. A method of constructing a wall, the method including the steps of: pre-forming wall segments, each wall segment being rectangular in cross section and having at least one vertical channel extending therethrough; locating a wall segment at a required location; sequentially mounting additional wall segments atop the first wall segment to form the wall; locating reinforcing rods within the vertically extending channel(s) of the wall segments; and filling the vertically extending channel(s) with a curable substance.
 12. A method of constructing a building wall as claimed in claim 11, wherein the method includes the further steps of: preforming footing blocks, each footing block being L-shaped in cross section and having at least one vertical channel extending through a vertical portion thereof; and locating the first wall segment atop the footing blocks such that the vertically extending channel(s) of the wall segment aligns with that of the footing blocks.
 13. A method of constructing a building column, the method including the steps of: pre-forming column segments, each column segment being T-shaped in cross section and having at least one vertical channel extending therethrough; locating a column segment at a required location within the building; sequentially mounting additional column segments atop the first column segment to form the building column; locating reinforcing rods within the vertically extending channel(s) of the column segments; and filling the vertically extending channel(s) with a curable substance.
 14. A method of constructing a building corner, the method including the steps of: pre-forming corner segments, each corner segment being L-shaped in cross section and having at least one vertical channel extending therethrough; locating a corner segment at a required location within the building; sequentially mounting additional corner segments atop the first corner segment to form the building corner; locating reinforcing rods within the vertically extending channel(s) of the corner segments; and filling the vertically extending channel(s) with a curable substance. 